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Installation, Operation,

And Maintenance Manual

Models BCF, HCF & SSCF


Fixed Tube Sheet Heat Exchangers
Table of Contents
Introduction and Safety.2
Introduction......2
Safety...2
Safety terminology and symbols.....2
User Safety ..3
General safety rules ..3
Safety equipment .. .4

Product Warranty .....4

Product Description...5
General description.......5

Installation....6
Installation ..............................6

Operation.6
Startup ..............................6

Maintenance........................ 7
Maintenance and cleaning Procedures....7

Storage
Storage ... 9

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 1
Introduction and Safety
INTRODUCTION
The purpose of this manual is to provide necessary information for:
-Installation
-Operation
-Maintenance

CAUTION:
Read this manual carefully before installing and using the product.
Improper use of the product can cause personal injury and damages to
property and may void the warranty.

NOTICE:
Save this manual for future reference, and keep it readily available at the
location of the unit.

SAFETY
WARNING:
-The operator must be aware of safety precautions to prevent physical injury.
-Operating, installing, or maintaining the unit in any way that is not covered in
this manual could cause death, serious injury, or damage to the equipment.
This includes any modification to the equipment or use of parts not provided
by Xylem. If there is a question regarding the intended use of the equipment,
please contact a Xylem representative before proceeding.
-Do not change the service application without the approval of an authorized
Xylem representative.

CAUTION:
You must observe the instructions contained in this manual. Failure to do so
could result in physical injury, damage, or delays.

Terminology and symbols


It is extremely important that you read, understand, and follow the safety
messages and regulations carefully before handling the product. They are
published to help prevent these hazards:
-Personal accidents and health problems
-Damage to the product
-Product malfunction

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 2
Hazard levels

DANGER:
A hazardous situation which, if not, avoided, will result in death or serious injury

WARNING:
A hazardous situation which, if not, avoided, could result in death or serious injury

CAUTION:
A hazardous situation which, if not, avoided, could result in minor or moderate
injury

NOTICE:
-A potential situation which, if not avoided, could result in undesirable conditions
-A practice not related to personal injury

Hazard categories
Hazard categories can either fall under hazard levels or let specific symbols
replace the ordinary hazard level symbols.

These are examples of other categories that can occur. They fall under the
ordinary hazard levels and may use complementing symbols:
-Crush hazard
-Cutting hazard
-Arc flash hazard

USER SAFETY
General safety rules
Applicable general safety rules:
-Always keep the work area clean.
-Pay attention to the risks presented by gas and vapors in work area.
-Avoid all electrical dangers and pay attention to the risks of electric shock or arc
flash hazards.
-Always bear in mind the risk of drowning, electrical accidents, and burn injuries.

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 3
Safety equipment
Use safety equipment according to the company regulations. Use this safety
equipment within the work area:
-Hard hat
-Safety goggles, preferably with side shields
-Protective shoes
-Protective gloves
-Gas mask
-Hearing protection
-First-aid kit
-Safety devices

NOTICE:
Never operate a unit unless safety devices are installed. Also see specific
information about safety devices in other chapters of this manual.

PRODUCT WARRANTY
Coverage
Xylem undertakes to remedy defects in products from Xylem under these
conditions:
-The faults are due to defects in design, materials, or workmanship.
-The faults are reported to a local sales and service representative within the
warranty period.
-The product is used only under the conditions that are described in this manual.
-All service and repair work that is done by Xylem authorized personnel.
-Genuine Xylem parts are used.

Limitations
Warranty does not cover defects caused by:
-Deficient maintenance
-Improper installation
-Modifications or changes to the product and installation that are made without
consulting a Xylem authorized representative
-Incorrectly executed repair work
-Normal wear and tear

Xylem assumes no liability for the following situations:


-Bodily injury
-Material damages
-Economic losses

Warranty claim
Xylem products are high quality products with expected reliable operation and long
life. However, should the need for a warranty claim arise, contact your local sales
representative or the manufacturer.

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 4
Product Description
GENERAL DESCRIPTION
BCF, HCF & SSCF heat exchangers are fixed tube heat
exchangers using 1/4", 3/8 and 5/8 diameter tubes. BCF
units use copper tubes, brass shells and CI bonnets. SSCF
units are made of all 316 S/S materials. Material options
exist for both products. Tubes are roller expanded into the
tube sheets.

5
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual
12.Location of the operating fluids in the heat exchanger can be a
function of the application. A few tips for the location of the
operating fluids are:
a. As a cooler, the preferred arrangement is with the hot
medium through the shell and the cooling medium through
the tubes. When the hot fluid is dirty or fouling, it is better to
put it through the tubes because they are easier to clean.
With single pass units be sure the shell inlet is on the same
end as the tube side outlet. In two pass units, the shell inlet
should be at the inlet-outlet bonnet end. It is customary for
the cooling medium to enter the lower bonnet connection,
although this can be reversed if necessary.
b. As a heater, the hot medium, usually steam or hot water,
must be in the shell. If it is steam, either of the shell
connections, or both, can be used, dependent on the actual
entering velocities.
INSTALLATION c. For the above applications and for temperatures above
1. Before installing this equipment, environment and service 150F, the higher temperature fluid should be circulated
conditions should be checked for compatibility with materials of through the shell side of the exchanger and precaution
construction. Contact your nearest Xylem Representative if you should be taken to avoid shock from abrupt changes in fluid
are not sure what the actual materials of construction are. circulation temperatures.
2. Provide valves and by-passes in the piping system so that both 13.Steam hammer can cause serious damage to the tubes of any
the shell and tube sides may be by-passed to permit inspection heat exchanger. A careful consideration of the following points
or repair. before an installation is made can prevent costly repairs which
3. Provide thermometer well and pressure gauge connections in all may be caused by steam hammer.
piping to and from the unit and locate as near the unit as a. A vacuum breaker and/or vent, should be used in accordance
possible. with the type of steam system installed.
4. Provide convenient means for frequently cleaning the unit as b. The proper trap for the steam system installed should be
suggested under Maintenance. used.
5. Provide necessary air vent cocks for units so they can be c. The trap and the condensate return line to the trap should be
purged to prevent or relieve vapor or gas binding of either the properly sized for the total capacity of the convertor.
tube or the shell sides. d. The trap should be sized for the pressure at the trap, not the
6. Foundations must be adequate so that exchangers will not settle inlet pressure to the steam controller.
and cause piping strains. Foundation bolts should be set to e. The trap must drain into an unpressurized condensate return
allow for setting inaccuracies. In concrete footings, pipe sleeves system. Condensate return lines must not be run at an
at least one size larger than bolt diameter slipped over the bolt elevation above the bottom of the heat exchanger. To do so
and cast in place are best for this purpose, as they allow the bolt may result in a buildup of the condensate level in the heat
center to be adjusted after the foundation has set. exchanger, which could cause water hammer and damaged
7. Loosen foundation bolts at one end of unit to allow free tubes.
expansion of shells. Oval holes in foundation brackets are
provided for this purpose. CAUTION: During times of shutdown, volumetric expansion
8. Set exchangers level and square so that pipe connections may can occur. We recommend the installation of a properly sized relief
be made without forcing. valve on both sides of the heat exchanger.
9. Inspect all openings in exchanger for foreign material. Remove
OPERATION
all thread protectors and shipping pads just before installing. Do
1. When placing a unit in operation, open the vent connections and
not expose units to the elements with pads or other covers
start to circulate the cold medium only. Be sure that the
removed from openings since rain water may enter the unit and
passages in the exchanger are entirely filled with the cold fluid
cause severe damage due to freezing.
before closing the vents. The hot medium should then be
10.Be sure the entire system is clean before starting operation to
introduced gradually until all passages are filled with liquid,
prevent plugging of tubes with sand or refuse. The use of
close vents and slowly bring the unit up to temperature.
strainers in settling tanks in pipe lines leading to the unit is
2. Start operation gradually. Do not admit hot fluid to the unit
recommended.
suddenly when empty or cold. Do not shock unit with cold fluid
11.Drain connections should not be piped to a common closed
when unit is hot.
manifold.
CAUTION: Fluids must be gradually introduced to the unit.
Failure to do so can cause damage to the heat exchanger.

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 6
3. In shutting down, flow of hot medium should be shut off 5. Do not blow out heat exchangers with air when operating
first. If it is necessary to stop circulation of cooling medium fluids are of a flammable or otherwise hazardous nature.
the circulation of hot medium should also be stopped by
by-passing or otherwise. WARNING: Proper precautions must be taken (special
clothing, equipment, etc.) to protect personnel from injury
4. Do not operate equipment under conditions in excess of
due to escaping fluids.
those specified on nameplate.

WARNING: Failure to operate the heat exchanger f. Provide convenient means for frequently cleaning heat
within the design pressure and temperature on the exchangers as suggested below:
nameplate may result in damage to the heat exchanger and a. Circulating hot wash oil or light distillate through tubes
potential injury to adjacent personnel. or shell at good velocity will effectually remove sludge or
other similar soft deposits.
5. Drain all fluids when shutting down to eliminate possibility
of freezing and corrosion. To guard against water b. Soft salt deposits may be washed out by circulating hot
hammer, condensate should be drained from steam fresh water.
heaters and similar apparatus both when starting up and
c. Some cleaning compounds on the market, such as
when shutting down.
Oakite may be used to advantage for removing sludge
6. In all installations there should be no pulsation of fluids or coke, provided hot wash oil or water, as described
since this causes vibration and strain with resulting leaks. above, does not give satisfactory results.
7. All gasketed joints should be checked after starting for d. If none of the above described methods are effective for
leaks and tightened if necessary. the removal of hard scale or coke a mechanical means
may be used. The interior of the tubes may be rodded.
WARNING: The BCF, HCF & SSCF exchangers are
suit able for use as heaters using steam as the heating e. The exterior or shell side of the tubes of a fixed sheet
medium. These exchangers are, however, fixed tubesheet heat exchanger can only be cleaned chemically by
units and, therefore, not designed to absorb thermal shock using a chemical dissolved in water solution. We
inherent in the intermittent service of on and off heating with suggest that the user contact the manufacturer of the
frequent short intervals of demand. Their recommended use cleaning chemical for instructions.
is where service is continuous or steady, with relatively long
periods between shutdown and start-up. Heat exchanger WARNING: Proper precautions must be taken (special
failure due to thermal shock may result in potential personal clothing, equipment, etc.) to protect personnel from injury
injury. due to escaping fluids.
MAINTENANCE
1. Do not open heads until all pressure is off equipment and
the unit is drained.

2. Remove the bonnets. Inspect all tubes carefully for 7. When replacing heads, use a torque wrench.* Tighten 1/4
possible erosion, corrosion, or foreign material. diameter bolts (2 diameter units) to 6 ft-lbs., 5/16
diameter bolts (3" & 4" diameter units) to 16 ft-lbs., and 3/8
3. Inspect all anodes to be sure they are neither excessively
diameter bolts (5", 6", & 8" diameter units) to 24 ft-lbs. If the
corroded nor insulated with scale. Scrape to a bright
gasket joint still leaks, tighten in 2 ft-lb. increments until
surface.
leak stops.
4. Inspect filters in the system to prevent foreign matter from *The above torque values apply to well lubricated nut
entering the exchanger. bearing surfaces.

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 7
8. All bolted joints should be tightened uniformly and in a 10.Exchangers subject to fouling or scaling should be cleaned
diametrically staggered pattern as illustrated below: periodically. A light sludge or scale coating on the tube
START
greatly reduces its effectiveness. Therefore, low-fouling
fluids should be used in the shell side of all heat
exchangers with non-removable tube bundles. A marked
1 16
11
increase in pressure drop and/or reduction in performance
6
usually indicates cleaning is necessary, especially if the
9 8 unit has been checked for air or vapor binding and this has
been found not to be the cause. Since the difficulty of
14 3
cleaning increases rapidly as the scale thickens or deposits
increase, the interval between cleanings should not be
4 13
excessive. interior and exterior condition should be
according to scale build-up.
7 10

12 5
15
2

9. Frequently and at regular intervals, observe interior and


exterior condition should be according to scale build-up. ANODES
1. Some exchangers may be equipped with renewable
CAUTION: Neglect in keeping all tubes clean may result anodes. The purpose of the anodes is to inhibit electrolytic
in complete stoppage of flow through some tubes with corrosion. In order to remain active the anodes must be
consequent overheating of these tubes, resulting in severe kept free of scale or other surfaces coatings.
expansion strains, leaking tube joints, and damage to the heat
exchanger. 2. On some applications where electrolytic corrosion is not a
problem, pipe plugs may be substituted for the anode. The
pipe plug material selected should be softer than the base
part to avoid pipe thread damage.
FRONT HEAD GASKET
CORE
(BUNDLE & SHELL ASSEMBLY) REAR HEAD
FRONT HEAD

REAR HEAD GASKET

RENEWABLE ANODES
(ZINC)

MOUNTING LEGS

BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 8
Storage
NOTE: If the heat exchanger cannot be installed and put into operation immediately upon receipt at the jobsite, certain
precautions are necessary to prevent deterioration during storage. Responsibility for integrity of the heat exchangers
must be assumed by the user. Xylem will not be responsible for damage, corrosion or other deterioration of heat
exchanger equipment during transit and storage. Good storage practices are important, considering the high costs of
repair or replacement, and the possible delays for items which require long lead times for manufacture. The following
suggested practices are provided solely as a convenience to the user, who shall make his own decision on whether to
use all or any of them.
1. On receipt of the heat exchanger, inspect for shipping damage to all protective covers. If damage is evident,
inspect for possible contamination and replace protective covers as required. If damage is extensive, notify the
carrier immediately.
2. If the heat exchanger is not to be placed in immediate service, take precautions to prevent rusting or contamination.
3. The choice of preservation of interior surfaces during storage for other service applications depends upon your
system requirements and economics. Only when included in the original purchase order specifications will specific
preservation be incorporated prior to shipment from the factory.
4. Remove any accumulations of dirt, water, ice or snow and wipe dry before moving exchangers into indoor storage.
If unit was not filled with oil or other preservative, open drain plugs to remove any accumulated moisture, then
reseal. Accumulation of moisture usually indicates rusting has already started and remedial action should be taken.
5. Store under cover in a heated area, if possible. The ideal storage environment for heat exchangers and
accessories is indoors, above grade, in a dry, low humidity atmosphere which is sealed to prevent entry of blowing
dust, rain or snow. Maintain temperatures between 70F and 105F (wide temperature swings may cause
condensation and sweating of steel parts). Cover windows to prevent temperature variations caused by sunlight.
Provide thermometers and humidity indicators at several points, and maintain atmosphere at 40% relative humidity
or lower.
6. In tropical climates, it may be necessary to use trays of renewable desiccant (such as silica gel), or portable
dehumidifiers, to remove moisture from the air in the storage enclosure. Thermostatically controlled portable
heaters (vented to outdoors) may be required to maintain even air temperatures inside the enclosure.
7. Inspect heat exchangers and accessories frequently while they are in storage.
If paint deterioration begins, as evidenced by discoloration or light rusting, consider touch-up or repainting. If the
unit is painted with our standard shop enamel, areas of light rust may be wire brushed and touched-up with any
good quality air-drying synthetic enamel. Units painted with special paints (when specified on customers Obtain
specific information from the paint manufacturer. Painted steel units should never be permitted to rust or deteriorate
to a point where their strength will be impaired. A light surface rust, on steel units which can be repainted after
installation, will not generally cause any harm. (See Items 3 and 4 for internal surface preservation.)
10.If the internal preservation (Items 3 and 4) appears inadequate during storage, consider additional corrosion
prevention measures and more frequent inspections. Interiors coated with rust preventive should be restored to
good condition and recoated promptly if signs of rust occur.
11.In shutting down, flow of hot medium should be shut off first. If it is necessary to stop circulation of cooling medium
the circulation of hot medium should also be stopped by bypassing or otherwise.
12.Drain all fluids when shutting down to eliminate the possibility of freezing and corrosion. To guard against water
hammer, condensate should be drained from steam heaters and similar apparatus both when starting up and when
shutting down.
13.Heat exchangers that are out of service for extended periods of time should be protected against corrosion as
described in the storage requirements for new heat exchangers.
Xylem Inc.
175 Standard Parkway
Cheektowaga, NY 14227
Tel: 1-800-447-7700
Fax: 1-716-897-1777
www.xyleminc.com
Lit #SC 2014
BCF HCF & SSCF Heat Exchangers Installation, Operation, and Maintenance Manual 9